Method and System for Forming Packages

ABSTRACT

A method of sealing reinforced packages. The method can comprise moving an open-ended package in a downstream direction on a package conveyor by engaging the open-ended package with a chain flight of the package conveyor moving in the downstream direction. The method further can comprise forming a bag with a closed end by engaging at least a seal portion of a tail section of an open-ended tube portion of the open-ended package between the chain flight of the package conveyor and a hot plate positioned adjacent the package conveyor. The chain flight can move with the tail section in the downstream direction relative to the hot plate, which can transfer thermal energy to the tail section to at least partially form a seal along the seal portion in the tail section to at least partially form the closed end of the bag.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/410,202, filed on May 13, 2019, which claims the benefit of U.S.Provisional Patent Application No. 62/671,032, filed on May 14, 2018.

INCORPORATION BY REFERENCE

The disclosures of U.S. patent application Ser. No. 16/410,202, whichwas filed on May 13, 2019, U.S. Provisional Patent Application No.62/671,032, which was filed on May 14, 2018, U.S. Provisional PatentApplication No. 62/179,172, which was filed on Apr. 29, 2015, and U.S.patent application Ser. No. 15/142,103, which was filed on Apr. 29,2016, are hereby incorporated by reference for all purposes as ifpresented herein in their entirety.

BACKGROUND OF THE DISCLOSURE

The present disclosure generally relates to reinforced packages forholding products and to methods of forming the packages. Morespecifically, the present disclosure is directed to methods and systemsfor forming the packages including a reinforcing sleeve for supporting abag.

Bags, such as paper or plastic bags, traditionally have been used forthe packaging and transport of products from bulk materials such as riceor sand to larger items. Bags generally are cheap and easy tomanufacture and can be formed in different configurations and sizes, andcan be used for storage and transport of a wide variety of products. Inparticular, in the Fast Food industry, bags are frequently used forpackaging of prepared food items, such as sandwiches, etc. Currently,there is a growing demand for bags or similar packages for use inpackaging various products, including sandwiches, French fries, andother prepared food items, that a worker can easily open, such as withone hand, and have the bag supported in an open configuration to enhancethe efficiency of packaging of such products. However, it is equallyimportant that the costs of such bags necessarily must be minimized asmuch as possible. While various bag designs including reinforcing orsupporting materials have been developed, often, the manufacture of suchspecialty bags having reinforcing layers or materials supplied theretohas required multiple stages or operations, which can significantlyincrease the cost of manufacture of such bags.

SUMMARY OF THE DISCLOSURE

In general, one aspect of the disclosure is directed to a method ofsealing reinforced packages. The method can comprise moving anopen-ended package in a downstream direction on a package conveyor. Theopen-ended package can include a reinforcement sleeve attached to anopen-ended tube portion so that a tail section of the open-ended tubeportion extends from an edge of the reinforcement sleeve. The open-endedsleeve can be oriented so that the tail section is disposed upstreamfrom the reinforcement sleeve. The moving the open-ended package cancomprise engaging the open-ended package with a chain flight of thepackage conveyor moving in the downstream direction. The method furthercan comprise forming a bag with a closed end by engaging at least a sealportion of the tail section of the open-ended tube portion between thechain flight of the package conveyor and a hot plate positioned adjacentthe package conveyor. The chain flight can move with the tail section inthe downstream direction relative to the hot plate. The forming the bagcan comprise transferring thermal energy from at least the hot plate tothe tail section during the engaging at least the seal portion of thetail section between the chain flight and the hot plate to at leastpartially form a seal along the seal portion in the tail section to atleast partially form the closed end of the bag.

In another aspect, the disclosure is generally directed to a system forsealing reinforced packages. The system can comprise a package conveyorcomprising a chain flight moving in a downstream direction. The chainflight can engage an open-ended package received by the package conveyorand can move the open-ended package in the downstream direction. Theopen-ended package can include a reinforcement sleeve attached to anopen-ended tube portion so that a tail section of the open-ended tubeportion extends from an edge of the reinforcement sleeve. The systemfurther can comprise a hot plate assembly comprising a hot platepositioned adjacent at least a portion of the package conveyor so thatat least a seal portion of the tail section of the open-ended tubeportion is engaged between the chain flight and the hot plate when thepackage conveyor moves the open-ended package in the downstreamdirection. The hot plate can be at least partially heated fortransferring thermal energy to the tail section for at least partiallyforming a seal in the tail section.

In another aspect, the disclosure is generally directed to at least apackage conveyor and a hot plate assembly that cooperate to at leastpartially form a reinforced package with a closed end from an open-endedpackage. The package conveyor can comprise a pusher lug and a chainflight moving in a downstream direction, the package conveyor receivingan open-ended package for engaging the pusher lug with at least aportion of the open-ended package for moving the open-ended package inthe downstream direction. The hot plate assembly comprising a hot platepositioned adjacent at least a portion of the package conveyor so thatat least a portion of a tail section of an open-ended tube portion ofthe open-ended package is engaged between the chain flight and the hotplate when the package conveyor moves the open-ended package in thedownstream direction. The hot plate being at least partially heated fortransferring thermal energy to the tail section for forming at leastpartially a seal in the tail section.

In another aspect, the disclosure is generally directed to a method ofsealing reinforced packages. The method comprises moving an open-endedpackage in a downstream direction on a package conveyor. The open-endedpackage including a reinforcement sleeve attached to a tube portion sothat a tail section of the tube portion extends from an edge of thereinforcement sleeve and comprises a seal portion. The moving theopen-ended package comprising engaging the open-ended package with aflight of the package conveyor moving in the downstream direction. Themethod comprises forming a bag with a closed end by engaging at leastthe seal portion of tube portion between the flight of the packageconveyor and a heating element positioned adjacent the package conveyor.The flight moving with the tail section in the downstream directionrelative to the heating element. The forming the bag comprisingtransferring thermal energy from at least the heating element to thetail section to at least partially form a seal along the seal portion inthe tail section to at least partially form the closed end of the bag.

In another aspect, the disclosure is generally directed to a system forsealing reinforced packages. The system comprising a package conveyorcomprising a flight moving in a downstream direction. The flightengaging an open-ended package received by the package conveyor andmoving the open-ended package in the downstream direction. Theopen-ended package including a reinforcement sleeve attached to a tubeportion so that a tail section of the tube portion extends from an edgeof the reinforcement sleeve and comprises a seal portion. A heatingassembly comprises a heating element positioned adjacent at least aportion of the package conveyor so that at least the seal portion of thetube portion is engaged between the flight and the heating element whenthe package conveyor moves the open-ended package in the downstreamdirection. The heating element is at least partially heated fortransferring thermal energy to the tail section for at least partiallyforming a seal in the tail section.

Additional aspects, features, and advantages of the present inventionwill become apparent from the following description and accompanyingfigures.

BRIEF DESCRIPTION OF THE DRAWINGS

Those skilled in the art will appreciate the above stated advantages andother advantages and benefits of various additional embodiments readingthe following detailed description of the embodiments with reference tothe below-listed drawing figures. It is within the scope of the presentdisclosure that the above-discussed aspects be provided bothindividually and in various combinations.

According to common practice, the various features of the drawingsdiscussed below are not necessarily drawn to scale. Dimensions ofvarious features and elements in the drawings may be expanded or reducedto more clearly illustrate the embodiments of the disclosure.

FIG. 1 is a perspective side view of a reinforced package in a flattenedcondition formed according to a system and method of forming reinforcedpackages according to an exemplary embodiment of the disclosure

FIG. 2 is a plan view of a blank for forming a reinforcing construct ofthe reinforced package of FIG. 1.

FIGS. 3 and 4 are perspective views of the reinforced package of FIG. 1in an opened condition.

FIG. 5 is a schematic illustration of a system and method of formingopen-ended packages according to the exemplary embodiment of thedisclosure.

FIGS. 6 and 7 are schematic perspective views of a system for sealingthe packages formed by the system of FIG. 5 according to the exemplaryembodiment of the disclosure.

FIG. 8 is a schematic perspective view of the system of FIGS. 6 and 7 inan open configuration according to the exemplary embodiment of thedisclosure.

FIG. 9 is a schematic perspective view of a carrier flight of the systemof FIGS. 6-8 according to the exemplary embodiment of the disclosure.

FIG. 10 is a schematic perspective view of a package conveyor, hot plateassembly, and nip roller of the system of FIGS. 6-8 according to theexemplary embodiment of the disclosure.

FIGS. 11A and 11B are schematic perspective views showing the engagementof the carrier flight of FIG. 9 with a package and moving the package onthe conveyor assembly of FIG. 10 according to the exemplary embodimentof the disclosure.

FIG. 12 is a schematic perspective view of a package on the packageconveyor and engaging the carrier flight of FIG. 9 according to theexemplary embodiment of the disclosure.

FIG. 13 is a schematic cross-sectional view showing the package engagedbetween the carrier flight and s hot plate of the hot plate assemblyaccording to the exemplary embodiment of the disclosure.

FIG. 14 is a schematic perspective view showing a package engagedbetween the carrier flight and the nip roller according to the exemplaryembodiment of the disclosure.

FIG. 15 is a schematic perspective view showing a carrier flight on thepackage conveyor engaging a pre-heater plate according to the exemplaryembodiment of the disclosure.

Corresponding parts are designated by corresponding reference numbersthroughout the drawings.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

The present disclosure generally relates to a system and method offorming reinforced packages for holding products such as food productsor other articles. Packages according to the present disclosure canaccommodate articles of any shape. The packages can comprise a bag orliner comprising a relatively flexible material attached to areinforcing construct comprising a relatively rigid material (e.g.,paperboard). The bags can generally be made from a paper, plastic,laminate, or other stock material and can be attached to the reinforcingconstruct that can be located between the opened end and sealed orclosed end of the bag. In one embodiment, the bags comprise polyethylenematerial or any other suitable heat-sealable material. The reinforcingconstruct can be of varying widths and can extend about or over theclosed ends of the bags, in some embodiments enclosing such closed ends,and will provide support for the bags upon loading with a product orarticle or series of articles therein. In some embodiments, thereinforcing constructs can be folded with their bags into aconfiguration supporting the bags in a freestanding, upright, and openedcondition for ease of loading.

FIG. 1 illustrates a reinforced package generally indicated at 1 thatcan be formed by one embodiment of the system and method of the presentdisclosure. The package 1 includes a bag 3 and a reinforcing constructor sleeve 5 attached to the bag 3. The bag has an open end 7, a closedend 9, and an interior space 17 for holding a product. In oneembodiment, the bag 3 has gusseted sides 60 including a fold line 61(FIGS. 3 and 4) extending the length of the bag on each side tofacilitate forming the gusseted side. The gussets 60 can extend betweena central portion 63 (e.g., the front of the bag 3) and respectivemarginal portions 65, 67, which can form the back of the bag 3. In theillustrated embodiment, the marginal portions 65, 67 can be at leastpartially overlapped with one another and adhered to one another to forma longitudinal seam 71 extending along the height of the bag 3 (FIG. 4).The interior space 17 may be accessible through a notch 15 in the bag 3.The reinforcing sleeve 5 is configured to at least partially receive aportion 11 of the closed end 9 of the bag 3. Alternatively, thereinforcing sleeve 5 could be positioned to extend around the middleportion or top portion of the bag 3 without departing from thedisclosure.

As shown in FIG. 1, the bag 3 can include a tail section 73 that extendsoutwardly from the sleeve 5 opposite to the open end 7 of the bag 3. Asdescribed in more detail below, the walls (e.g., the gussets 60, thecentral portion 63, and the marginal portions 65, 67) can been heatsealed and/or adhered together along the tail section 73 to at leastpartially form a transverse seal or seam 69 that at least partiallyforms the closed end 9 of the bag 3.

FIG. 2 illustrates a blank 10 for forming the reinforcing sleeve 5. Theblank has a lateral axis L1 and a longitudinal axis L2. In theillustrated embodiment, the blank 10 has a front panel 21 foldablyconnected to a first side panel 28 at a first arcuate fold line 33. Thefirst side panel 28 includes two individual panel portions 28A, 28Bfoldably connected to one another at a lateral fold line 26. A firstback panel 23 is foldably connected to the first side panel 28 at asecond arcuate fold line 31. A second side panel 29 is foldablyconnected to the front panel 21 at a third arcuate fold line 35. Thesecond side panel 29 includes two individual panel portions 29A, 29Bfoldably connected to one another at a lateral fold line 27. A secondback panel 25 is foldably connected to the second side panel 29 at afourth arcuate fold line 37. In the illustrated embodiment, the arcuatefold lines 31, 33 are spaced apart from the lateral fold line 26 and areconcave with respect to the lateral fold line 26. Similarly, the arcuatefold lines 35, 37 are spaced apart from the lateral fold line 27 and areconcave with respect to the lateral fold line 27. In alternativeembodiments, the blank 10 can have alternative panel, fold line, and/orpanel portion arrangements. U.S. patent application Ser. No. 13/826,937,filed Mar. 14, 2013, is incorporated by reference herein for allpurposes, and illustrates various reinforced packages including variousreinforcing constructs 5, blanks 10, and bags 3 that can be formed fromthe method and system of the present disclosure.

In the illustrated embodiment, the blank 10 can include one or moreadhesive regions 41, 43, and 45 on the first back panel 23, front panel21, and/or second back panel 25, respectively, for receiving adhesiveand being fixedly attached to an exterior surface of the bag 3.Furthermore, the blank 10 has a first edge 52 and a second edge 53extending in the longitudinal direction L2. In one embodiment, theadhesive regions 41, 43, 45 are separated from the first edge 52 by afirst distance D1 and are separated from the second edge 53 by a seconddistance D2. In one embodiment, the first distance D1 is less than thesecond distance D2. The first and second side panels 28, 29 and regionsseparate from the adhesive regions 41, 43, 45 may be generally free fromadhesive in some embodiments, or may include adhesive in alternativeembodiments. Additionally, the first and second distances D1, D2,adhesive regions 41, 43, 45, and/or edges 52, 53 can be otherwisearranged, shaped, modified, or omitted without departing from the scopeof this disclosure. For example, the first distance D1 and the seconddistance D2 could be generally equal or the first distance D1 could begreater than the second distance D2.

Generally, the blank 10 may be folded about fold lines 26, 27 to createthe reinforcing sleeve 5. For example, distal ends 55, 57 of the firstand second back panels 23, 25 may be overlapped, and the sleeve 5attached to the bag 3 as illustrated in FIGS. 1, 3, and 4. In oneembodiment, the glue regions or another adhesive can extend into one orboth of the distal ends 55, 57 so that the overlapped portions of theback panels 23, 25 are adhered to one another when the reinforcementsleeve 5 is formed. The individual panel portions 28A, 28B, 29A, and 29Bmay be in face-to-face registration in a first, non-erect position ofthe bag 3 as illustrated in FIG. 1. The first, non-erect positionillustrated reduces and/or minimizes a volume of the interior space 17such that the package 1 is in a non-erect or flattened state. Thenon-erect state may facilitate easy stacking of a plurality of packagesinto, for example, a shipment container and subsequent organization at adestination facility. The individual panel portions 28A, 28B, 29A, and29B may be flexed or positioned to form first and second sides 58, 59 ofthe package 1 in a second, erect position of the bag 3 as illustrated inFIGS. 3 and 4. The second, erect position illustrated increases and/ormaximizes a volume of the interior space 17 such that the package 1 isin an erect or self-supporting state. The tail section 73, including theclosed end 9, of the bag 3 can extend upwardly into an interior 56 ofthe sleeve 5 in the direction of arrow A1 while the package is in theerect state (FIG. 3). Furthermore, the bottom edge 53 forms a supportwhen the package 1 is in the erect state for contacting a surface S(FIG. 4). The support formed of the bottom edge 53 maintains the packagein an upright position on the surface S. As further illustrated in FIGS.3 and 4, the gusseted sides 60 of the bag 3 may be maintained extendedwhen the package 1 is in the erect state. Other intervening states ofthe package 1 including intermediate states whereby the package 1 is notfully erected are also applicable according to some embodiments.Furthermore, additional reinforcing sleeves of differing configurationsare also applicable according to some embodiments. The reinforcedpackage 1 may be otherwise shaped, arranged, and configured withoutdeparting from the disclosure.

FIG. 5 generally illustrates an example embodiment of a system andmethod 100 for forming the reinforced packages (e.g., reinforcedpackages 1) in accordance with the disclosure. In the illustratedembodiment, the packaging system 100 attaches a web of material 101 forforming the bags 3 of the packages 1 to the blanks 10, and the attachedblanks and web move through the packaging system 100 from an upstreamend 103 to a downstream end 105 generally in a machine direction M(e.g., the downstream direction), and are formed into the individualpackages by various portions and components of the system as discussedfurther below. The system 100 can be similar or identical to the systemsdisclosed in U.S. patent application Ser. No. 15/142,103, filed Apr. 29,2016, which is incorporated by reference herein for all purposes.Alternatively, the reinforced packages 1 could be otherwise formedwithout departing from the disclosure.

As illustrated in FIG. 5, in the system and method 100 for manufacturingreinforced packages 1, the web of bag material 101, which can includepreprinted or unprinted paper, polyethylene, laminates, or othermaterial including flexible and heat-sealable materials, for example, isfed from a roll or supply 102. In one embodiment, the bag material 101can be preprinted with various designs, lettering, labels and/or othergraphics and can have a heat sealable coating (e.g., polyethylene) on asurface (e.g., the surface that extends along the interior of the bag3). In other embodiments, the bag material 101 can be perforated,printed roll stock that can include patterned adhesive that ispositioned to facilitate forming the web 101 into bags 3 in the formedpackages 1.

In one embodiment, a carton feeder 107 is positioned at the upstream end103 of the system 100 and includes a stack 108 of carton blanks 10 thatare fed to a blank conveyor 109. As illustrated in FIG. 5, the cartonfeeder 107 is a pick and place type carton feeder that includes an arm110 with suction cups or any other suitable actuator for holding a blank10 and moving the blank from the stack 108 to the blank conveyor 109.Alternatively, the carton feeder could comprise other types of feederssuch as mechanisms that convey blanks 10 directed from a blank cuttingstation, or any other suitable types of feeders or other mechanismswithout departing from the disclosure.

As shown in FIG. 5, the blank conveyor 109 includes two spaced apart lugbelts or tracks 111 with lugs 113 for engaging a series of blanks 10 andconveying the blanks in the machine direction M. In the illustratedembodiment, the lug belts 111 can be endless belts, each with aplurality of the lugs 113 spaced along the respective belt. In oneembodiment, the lugs 113 can be spaced on the lug belts 111 byapproximately the height of the bags 3 in the reinforced packages 1. Theblank conveyor 109 receives the blanks 10 from the carton feeder 107 andmoves the series of blanks 10 from the carton feeder 107 to be glued andattached to the bag material 101. In the illustrated embodiment, anadhesive applicator 116 can apply adhesive to the blanks 10 (e.g., atthe adhesive region 43), and the web of material 101 can be unrolledfrom the roll 102 over one or more rollers and directed to move in themachine direction over (e.g., generally parallel to) the lug belts 111so that the web of material 101 can be brought into contact with theblanks 10. In one embodiment, a compression nip roller 117 can bepositioned downstream from the adhesive applicator 116 over the web ofmaterial 101 and an opposing nip roller or other surface (not shown) canbe disposed below the blanks 10 so that the nip rollers can receive theweb of material 101 and the blanks 10 and press the web of material 101against the blanks 10 to adhesively attach the web to the blanks via theadhesive applied by the adhesive applicator 116, for example. In oneembodiment, the nip roller 117 and the opposing roller can be disposedbetween the lug belts 111 so that the lugs 113 can pass by the rollers.The blank 10 can be attached to the web 101 by other suitable mechanismswithout departing from the disclosure.

In one embodiment, as schematically shown in FIG. 5, the web 101 withblanks 10 attached (hereinafter the attached web W′) travels from theblank conveyor 109 through a series of rollers 121, 123 and to a tubeforming assembly 125 of the system 100. The tube forming assembly 125can include web folding features for forming the web of material 101into an open-ended tube 101′. In one embodiment, the tube formingassembly 125 can include a forming roll 126 and other guide features(not shown) that form and shape the web 101 into the tube 101′ havingthe side gussets 60 and fold lines 61 (FIGS. 3 and 4). In theillustrated embodiment, the marginal portions 65, 67 can be directed tofold upwardly and inwardly over and then to overlap one another whilethe gusset portions 60 are formed between the central portion 63 and theoverlapped marginal portions 65, 67. A web adhesive applicator 127 canapply adhesive to the web 101 as the web is being formed into the tube101′. The adhesive 72 can be applied to one or both of the marginalportions 65, 67 by the adhesive applicator 127 as they are overlapped toform a longitudinal seam 71 in the tube 101′ (FIGS. 1, 3, and 4). Theseam 71 could be otherwise formed without departing from the disclosure.Further, the tube forming assembly 125 could be otherwise configuredwithout departing from the disclosure.

In one embodiment, the attached web W′ moves from the tube formingassembly 125 to a carton forming assembly 131 of the system 100. In oneembodiment, the carton forming assembly 131 includes carton foldingfeatures (not shown) that position the various flaps and panels of theblank 10. In addition, the system 100 can include folders (not shown)for breaking the fold lines of the blank 10 (e.g., the arcuate foldlines 31, 33, 35, 37) between the tube forming assembly 125 and thecarton forming assembly 131. In one embodiment, the carton formingassembly 131 includes a carton adhesive applicator 135 that appliesadhesive to the blank 10 so that panels (e.g., the first back panel 23and the second back panel 25) can be folded (e.g., along fold lines 26,27), overlapped, and adhered to form the blank 10 into the reinforcementsleeve 5 as the attached web W′ moves through the carton formingassembly 131. Additionally, the back panels 23, 25 can be pressedagainst the tube (e.g., by nip rollers 137) so that an adhesive appliedat adhesive regions 41, 45 (FIG. 2) can attach the back panels to thetube. In one embodiment, the back panels 23, 25 can at least partiallyoverlap and can be adhered to one another. The carton forming assembly131 could be otherwise configured without departing from the disclosure.

As shown in FIG. 5, the system 100 includes a cutting assembly 151 withone or more cutting features downstream from the carton forming assembly131. In the illustrated embodiment, the cutting assembly is a rotarycutting assembly 151 that includes a cutting roller 153 and a baseroller 155 that cut the attached web W′ into open-ended packages 160including the sleeves 5 attached to respective open-ended tube portions147. In one embodiment, the cutting roller 153 can have an edge 157 orother cutting feature that is configured to cut the tube 101′. Theattached web W′ is cut and separated into the open-ended packages 160 bycutting the web material 101 at the location corresponding to the tailsection 73 of the open-ended package 160 and at the locationcorresponding to the top edge 7 of what will be the subsequentopen-ended package 160. In the illustrated embodiment, the cut is madein the tube to form the tail section 73 extending outwardly from thesleeve 5, past the bottom edge 53 so that the tail section 73 isexterior to the sleeve 5 (FIG. 1) at an upstream end of the respectiveopen-ended package 160. After the cut, the open-ended package 160,including the sleeve 5 and the open-ended tube portion 147 having anopen top end 7 and an open bottom end at the tail section 73, is nowseparated from the remainder of the attached web W′. The attached web W′can be cut and formed into the open-ended packages 160 by othermechanisms without departing from the disclosure. Further, the rotarycutting assembly 151 could be otherwise shaped, arranged, and/orconfigured without departing from the disclosure.

In an exemplary embodiment, once the open-ended packages 160, with thesleeves 5 and the open-ended tube portions 147, are formed by the system100, the open-ended packages 160 can be passed to the sealing system 200(FIGS. 6-15) for forming the transverse seal 69 in the tail section 73to form the open-ended tube portion 147 into the bag 3 for each of thereinforced packages 1. For example, the open-ended packages 160 can bepassed directly from the system 100 to the sealing system 200 by one ormore conveyors such as a belt conveyor 162 (FIG. 6). Alternatively, theopen-ended packages 160 can be stacked and can be stored and/ortransported to the sealing system 200 where the stacked open-endedpackages 160 can be introduced to the sealing system 200 by a feeder(not shown), which can be similar to the a carton feeder 107 of thesystem 100 (FIG. 5).

As shown in FIGS. 6-8, the sealing system 200 can include a packagefeeder 201, a package conveyor 203, and a heating assembly or hot plateassembly 205, each mounted to a base frame 206. In the illustratedembodiment, the package feeder 201 (e.g., FIGS. 6-8) can receive theopen-ended packages 160 from the system 100 (e.g., via the belt conveyor162) or from a stack of packages and can deposit the open-ended packages160 onto the package conveyor 203. Generally and as described in moredetail below, the package conveyor 203 can engage the open-endedpackages 160 and move them sequentially past the hot plate assembly 205for at least partially forming the transverse seal 69 on the tailsection 73. In the illustrated embodiment, the hot plate assembly 205can include one or more heating elements or hot plates 211 mounted on apivot frame 213, which can pivot from a closed position (e.g., FIGS. 6,7, and 13) to an open position (e.g., FIG. 8). The open position of thehot plate assembly 205 can facilitate making adjustments to the sealingsystem 200, as discussed in more detail below.

As shown in FIGS. 8-12, the package conveyor 203 includes two spacedapart lug belts or tracks 215 with pusher lugs 217 for engaging a seriesof the open-ended packages 160 (FIGS. 10-14) and conveying theopen-ended packages in the machine direction M. In one embodiment, thelug belts 215 can be driven by a motor 218, which can be mounted to thebase frame 206 (FIGS. 6, 7, and 10). In the illustrated embodiment, thelug belts 215 can be endless belts, each engaging a plurality of wheels,including upstream wheels 243 and downstream wheels 247. As shown inFIG. 10, the downstream wheels 247 can be driven by the motor 218 tomove the lug belt 215 on the wheels so that the lug belts 215 move inthe machine direction M on the top of the package conveyor 203 and movein a return direction R on a bottom side of the package conveyor 203. Inone embodiment, the other wheels can be idler wheels and/or could bedriven wheels. In the illustrated embodiment, the lug belts 215 can besupported in support tracks 220 along the top of the package conveyor203 and between the upstream wheels 243 and the downstream wheels 247.The support tracks 220 can be mounted on the base frame 206 in oneembodiment. As shown in FIG. 10, the pusher lugs 217 are spaced alongthe respective lug belt 215. In one embodiment, the pusher lugs 113 canbe spaced on the lug belts 111 by at least the height of the open-endedtube portions 147. As shown in FIGS. 8-15, the package conveyor 203 caninclude flights 219 such as chain flights 219 for engaging therespective tail sections 73 of the open-ended tube portions 147. Each ofthe chain flights 219 can extend transverse to the machine direction Mfrom a pusher lug 217 on one of the lug belts 215 to a pusher lug 217 onthe other lug belt 215. Accordingly, a flight 219 is associated witheach pair of pusher lugs 217 of the lug belts 215 in the illustratedembodiment. In an exemplary embodiment, the chain flight 219 can beaffixed to the lugs 217 by fasteners 222 (FIG. 14) or by an adhesive orcan be otherwise connected to or integral with the pair of pusher lugs217.

As shown in FIGS. 9 and 13, the chain flight 219 can have a first,recessed surface 221, a second, upper surface 223, and an obliquesurface 225 extending between the recessed surface 221 and the uppersurface 223. In the illustrated embodiment, the chain flight 219 can bea metal (e.g., aluminum) or other suitable material that can be heatedand that can suitably transfer thermal energy to the tail sections 73,as described in more detail below. In one embodiment, the aluminum ofthe chain flight 219 can remain exposed for more efficient heattransfer. Alternatively, a protective material (e.g., a tape or fabric)can be applied to the surface of the chain flight 219 to help preventscuffing of the open-ended packages 160, stickiness between theopen-ended packages 160 and the chain flight 219, and/or frictionbetween the open-ended packages 160 and the chain flight 219. Forexample, the protective material could be polytetrafluoroethylene or anyother suitable material (e.g., with a low coefficient of friction). Inone embodiment, the length (e.g., the dimension extending transverse tothe machine direction M) of the chain flight 219 can be at least equalto the length of the seam 69 to be formed on the tail section 73 (FIGS.1, 3, and 12). For example, in the case that the seam 69 extends acrossthe entire width of the bag 3 (e.g., as shown in FIGS. 1 and 3), thelength of the chain flight 219 can be greater than or equal to the widthof the tail section 73 (e.g., as shown in FIG. 12). Also as shown inFIG. 9, the end portions 269 of the chain flights 219 can extendupwardly at either end of the chain flight 219 and can have respectiveengagement surfaces 227 at their respective downstream sides. As shownin FIGS. 9 and 12, the end portions 269 each can have a notch thatreceives a respective lug 217 and engages the respective pusher lugs 217on two sides. The fasteners 222 (FIG. 14) can be threaded fasteners, forexample, and can secure the end portions 269 to the respective lugs 217.As shown in FIG. 12, the end portions 269 and the pusher lugs 217 can bespaced apart so that the distance between the end portions 269 isgreater than the width of the open-ended tube portion 147, but is lessthan the width of the sleeve 5. Accordingly, the spacing between the endportions 269 can provide clearance for the open-ended tube portion 147while the engagement surfaces 227 of the chain flights 219 engage thebottom edge 53 of the sleeve 5 (FIG. 12).

In one embodiment, as shown in FIGS. 12 and 13, the engagement surfaces227 of the end portions 269 can be generally aligned with the transitionbetween recessed surface 221 and the oblique surface 225 of the chainflight 219 so that the recessed surface 221 can engage the marginalportion of the sleeve 5 adjacent the bottom edge 53, which engages theengagement surfaces 227 of the end portions 269, and the oblique surface225 and the upper surface 223 can help elevate at least a portion of thetail section 73 relative to the remainder of the open-ended tube portion147 and the sleeve 5. As shown in FIG. 13, for example, the chain flight219 can engage the undersurfaces of the sleeve 5 and the tail section73. In the illustrated embodiment, as shown in FIGS. 12 and 13, thechain flight 219 can include a seal edge 229 configured to engage theundersurface of the tail section 73 at a seal portion SP of the tailsection 73, wherein the seal portion SP can comprise the location in thetail section 73 where the seal 69 will be formed. The seal edge 229 isshown in phantom in FIG. 12 where the seal edge is covered by the tailsection 73. In one embodiment, the engagement surfaces 227 of the endportions 269 can be spaced from the seal edge 229 of the chain flight219 according to the desired spacing between the bottom edge 53 of thesleeve 5 and the seam 69 of the bag 3. The seal edge 229 can have a sizeand shape corresponding to the desired size and shape of the seal 69.For example, the width of the seal edge 229 in the machine direction Mcan correspond to the thickness of the seal 69. The pusher lugs 217and/or the chain flights 219 could be omitted or could be otherwisearranged, shaped, positioned, or configured without departing from thescope of the disclosure. For example, the chain flight 219 could bewedge-shaped or could have any other suitable shape.

As shown in FIGS. 8-15, the package conveyor 203 further can includesupport rails 231 extending in the machine direction M between the lugbelts 215 and the support tracks 220. While two support rails 231 areshown in the figures, the package conveyor 203 could include one supportrail or any suitable number of support rails or the support rails couldbe omitted. The support rails 231 can support the open-ended packages160 and the chain flights 219 as they are moved in the machine directionM by the lug belts 215 (FIGS. 10-14). In one embodiment, each of thesupport rails 231 has an upper surface that is spaced below the lugbelts 215 to help provide clearance for the portions of the open-endedpackages 160 that are not engaged by the chain flight 219 to bedownwardly spaced from the hot plates 211 as the package conveyor 203moves the open-ended package 160 past the hot plates 211 (FIG. 13). Thisconfiguration can help to avoid unwanted sealing of the bag 3 byallowing the unsealed areas of the bag to be spaced from the hot plates211 while the open-ended package 160 rests on the support rails. Thepackage conveyor 203, including the lug belts 215, the pusher lugs 217,the chain flights 219, the support tracks 220, the wheels 243, 247,and/or the support rails 231, could be otherwise arranged, shaped,positioned, or configured without departing from the scope of thedisclosure.

As shown in FIGS. 7, 8, and 10, the heating assembly 205 can beconfigured to include four hot plates 211 (e.g., FIG. 7) or three hotplates 211 (e.g., FIGS. 8 and 10) mounted to the pivot frame 213 so thateach of the hot plates 211 has a bottom surface 232 (FIGS. 8 and 13)facing at least a portion of the package conveyor 203. As shown in FIGS.7 and 8, the pivot frame 213 can be mounted to the base frame 206 byhinges 233, which can allow the pivot frame 213 to pivot relative to thebase frame 206 between the closed position and the open position. In theillustrated embodiment, additional supports mounted to the base frame206 and/or the pivot frame 213 opposite to the hinges 233 can supportand/or latch the pivot frame 213 in the closed position. As shown inFIGS. 6 and 8, these additional supports can include a pair of liftapparatus 234 a, each of which can include a wheel mounted on a clevis,and which can be actuated (e.g., by a pneumatic actuator, hydraulicactuator, motor, or other suitable actuator) to push the pivot frame 213upwardly on the hinges 233 to facilitate opening of the pivot frame. Inone embodiment, the wheel of the lift apparatus 234 a can engagerespective brackets 234 b mounted on the pivot frame 213 when the pivotframe is in a closed position (FIGS. 6 and 7) or a partially closed orpartially open position. As shown in FIG. 8, additional supports 238 canbe mounted on the base frame 206 to support the pivot frame 213 in theclosed position (FIGS. 6 and 7). The pivot frame 213 could be omitted orcould be otherwise arranged, shaped, positioned, or configured withoutdeparting from the scope of the disclosure. For example, the hot plates211 could be otherwise supported relative to the package conveyor 203.

As shown in FIGS. 6 and 8, the heating elements or hot plates 211 can beconnected to a temperature controller 235 (e.g., via wires), which canbe mounted to the base frame 206, for heating the hot plates 211 andmaintaining the temperature of the hot plates 211 during the sealingprocess as described in more detail below. As shown in FIGS. 7, 10, and13, each of the hot plates 211 can be mounted to two heater elements 240(e.g., electrical resistance heaters or any other suitable heatingelements), which can be powered by the temperature controller 235 toheat the top plates 211 to the desired temperature for sealing the tailsections 73 of the open-ended sleeves 147. A thermocouple 244 canprovide feedback to the temperature controller for each hot plate 211(FIGS. 7, 10, and 13). Each of the heater elements 240 can be mounted totwo crossbars 246 by respective brackets 248 and the crossbars 246 canbe mounted to the pivot frame 213 to support the hot plates 211 as shownin FIGS. 7, 8, 10, and 13. The hot plates 211 could be otherwise heatedand/or mounted to the pivot frame 213 without departing from thedisclosure.

As shown in FIGS. 8, 10, 11A, and 11B, the hot plates or heatingelements 211 can have a width (e.g., the horizontal dimension that istransverse to the machine direction M) so that they fit between thepusher lugs 217 and so that they are at least as wide as the length ofthe seam 69 of the bag 3. For example, in the case that the seam 69extends across the entire width of the bag 3 (e.g., as shown in FIGS. 1and 3), the width of the hot plates 211 can be greater than or equal tothe width of the tail section 73. In one embodiment, a protectivematerial (e.g., a tape or fabric) can be applied to the hot plates 211(e.g., applied to at least the bottom surfaces 232 of the hot plates211) to help prevent scuffing of the open-ended packages 160, stickinessbetween the open-ended packages 160 and the bottom surfaces 232 of thehot plates 211, and/or friction between the open-ended packages 160 andthe bottom surfaces 232 of the hot plates 211. For example, theprotective material could be polytetrafluoroethylene or any othersuitable material (e.g., with a low coefficient of friction). The hotplate assembly 205 could be otherwise arranged, shaped, positioned, orconfigured without departing from the scope of the disclosure. Forexample, any suitable number of hot plates 211 could be mounted to thepivot frame 213.

As shown in FIGS. 7, 8, 10, and 14, a nip roll 236 is mounted to thepivot frame 213 at a downstream end of the heating assembly 205. In oneembodiment, the nip roll 236 is mounted to the pivot frame 213 by a niproll brace 250 (FIGS. 6-8 and 10) so that the nip roll 236 is free torotate about its axis. In the illustrated embodiment, the nip roll 236is positioned to extend between the lug belts 215 and the pusher lugs217 for engaging the tail section 73 as the package conveyor 203 movesthe packages in the downstream direction beneath the nip roll 236. Inone embodiment, the nip roll 236 can have a length (e.g., in thehorizontal direction that is transverse to the machine direction M) thatis generally equal to the width of the tail section 73. In an exemplaryembodiment, the nip roll 236 is configured so that at least a portion ofthe tail section 73 is engaged between the surface of the nip roll andthe seal edge 229 of the chain flight 219 as the chain flight 219 movespast the nip roll 236 on the lug belts 215 (FIG. 14). In the illustratedembodiment, the nip roll 236 has a compliant covering (e.g., a sleeve orcoating) so that the surface of the nip roll 236 can at least partiallyconform to the portions of the tail section 73 with differentthicknesses (e.g., the open-ended sleeve 147 and the bag 3 can have fourlayers of material where the gussets 60, the central portion 63, and therespective marginal portions 65, 67 overlap; three layers of materialwhere the central portion and the seam 71 overlap; and two layers ofmaterial where the central portion 63 overlaps each of the marginalportions 65, 67 between the gussets 60 and the seam 71). The nip roll236 could be omitted or could be otherwise arranged, shaped, positioned,or configured without departing from the scope of the disclosure.

In the illustrated embodiment, a pair of brushes 237 (e.g., a retentionassembly) can be mounted to the pivot frame via the crossbars 246 andcan extend in the machine direction M along the lug belts 215 (FIGS. 7,8, 11A, 11B, and 13). In one embodiment, the brushes 237 can be setoutside the pusher lugs 217 and the hot plates 211, and can be spacedapart in the horizontal direction that is transverse to the machinedirection M by a distance that is less than the width of the reinforcingsleeves 5. In addition, the brushes 237 can be positioned to engage theupper surfaces of the reinforcing sleeves 5 so that the brushes 237 pushdown on the reinforcing sleeves 5, which can help push the open-endedpackages 160 down against the lug belts 215, the support rails 231, andthe chain flights 219 (FIG. 13). Further, the brushes 237 can dragagainst the reinforcing sleeves 5, which can help maintain the bottomedges 53 of the reinforcing sleeves 5 against the engaging surfaces 227of the respective pusher lugs 217 as the pusher lugs 217 are moved inthe machine direction M by the lug belts 215. Accordingly, as shown inFIG. 13, the brushes 237 can help position the open-ended packages 160so that only the seal portions SP of the open-ended sleeves 147 are incontact with the heating elements 211 and so that the open-endedpackages 160 are properly aligned in the package conveyor 203 as thepackage conveyor 203 moves the open-ended packages 160 in the downstreamdirection.

In one embodiment, the brushes 237 can be aligned with outer portions ofthe respective lug belts 215 so that the lugs 217 and the outer portions269 of the chain flights 219 can pass immediately inside the brushes 237or near the inner sides of the brushes 237. In this configuration, thereinforcing sleeves 5 can be pressed between the brushes 237 and theouter portions of the lug belts 215 as the lug belts 215 and theopen-ended packages 160 move under the brushes 237 in the machinedirection M. In another embodiment, the lug belts 215 can be narrower(e.g., so that the width of the belts corresponds to the width of thelugs 217) and/or the brushes 237 can be mounted outside the widths ofthe lug belts 215. In this configuration, a static surface can extendunder each the brushes so that the open-ended packages 160 can bepressed between the brushes 237 and the static surfaces as theopen-ended packages 160, the chain flights 219, the lugs 217, and thelug belts 215 move in the machine direction M. In one example, thestatic surfaces can be upper surfaces of the support tracks 220 or astatic guide that can be similar to the support rails 231 mountedoutside the tracks 220. In some embodiments, while the brushes 237 canrestrain the open-ended packages 160 against the chain flights 219 bypressing the open-ended packages against the outer portions of the lugbelts 215, pressing the open-ended packages 160 between two staticfeatures (the brushes 237 and the static surfaces) can better restrainthe open-ended packages 160 against the chain flights 219 than pressingthe open-ended packages 160 against portions of the moving lug belts215.

In some embodiments, as shown in FIGS. 8, 11A, and 11B, the system 200can be configured to include only three hot plates 211 instead of four,and a pair of additional brushes 239 can be positioned inside thebrushes 237, upstream from the three hot plates 211 (e.g., approximatelywhere the fourth hot plate 211 is in FIG. 8). The additional brushes 239can help to align the open-ended packages 160 with the pusher lugs 217and the chain flights 219 and to seat the open-ended packages 160 on thepusher lugs 217 and the chain flights 219 at the upstream end of thesystem 200 (FIGS. 11A and 11B). In the illustrated embodiment, thebrushes 237, 239 are mounted to the pivot frame 213 via crossbars 246.Any of the brushes 237, 239 could be omitted or could be otherwisearranged, shaped, positioned, or configured without departing from thescope of the disclosure. For example, the brushes 237, 239 could bemounted to the base frame 206 or another suitable feature.

As shown in FIGS. 8 and 15, the system 200 can include a preheat plate241 mounted to the base frame 206 so that an upper surface 242 of thepreheat plate 241 faces an underside of the upstream end of the packageconveyor 203. In one embodiment, the preheat plate 241 can be connectedto the temperature controller 235 for heating the preheat plate 241(e.g., with a heating element) and for monitoring the temperature of thepreheat plate 241 (e.g., via a thermocouple). In the illustratedembodiment, the preheat plate 241 is positioned so that the chainflights 219 engage and/or contact the upper surface 242 of the preheatplate 241 as the lug belts 215 move the pusher lugs 217 and the chainflights 219 upstream, in the return direction R (e.g., opposite to themachine direction M) on the return portion (e.g., the underside) of thepackage conveyor 203. In one embodiment, at least the seal edge 229 ofthe chain flight 219 can contact the preheat plate 241 for transferringthermal energy from the preheat plate 241 to the chain flight 219. Inthe illustrated embodiment, the preheat plate 241 can be made ofaluminum or another suitable material and can be uncoated and uncoveredso that the metal of the chain flight 219 is in contact with the metalof the preheat plate 241 for efficient heat transfer from the preheatplate to the chain flight. Alternatively, a protective material (e.g., atape or fabric) can be applied to the preheat plate 241 (e.g., appliedto at least the upper surface 242 of the preheat plate 241) to helpprotect the chain flights 219 as they slide along the upper surface 242of the preheat plate 241. For example, the protective material could bepolytetrafluoroethylene or any other suitable material (e.g., with a lowcoefficient of friction).

In an exemplary embodiment, the preheating of at least the seal edge 229of the chain flight 219 prior to engaging the tail section 73 of theopen-ended tube portion 147 can help reduce the dwell time (e.g., thetime of contact between the tail section 73 of the bag 3 with the hotplates 211) needed for forming the seal 69 in the bag 3 such as inlocations with more than two layers of material (e.g., the open-endedsleeve 147 and the bag 3 can have four layers of material where thegussets 60, the central portion 63, and the respective marginal portions65, 67 overlap; three layers of material where the central portion andthe seam 71 overlap; and two layers of material where the centralportion 63 overlaps each of the marginal portions 65, 67 between thegussets 60 and the seam 71). For example, the preheated seal edge 229 ofthe chain flight 219 can transfer thermal energy to the undersurface ofthe tail section 73 that it engages while the hot plates 211 transferthermal energy to the upper surface of the respective tail section 73 toform the seal 69. In one embodiment, the reduced dwell time can allowthe total length of the hot plates 211 to be reduced and/or the speed ofthe packaging conveyor 203 to be increased and/or can help to reduceoverheating of thinner portions of the tail section 73. In one exemplaryembodiment, the system 200 that is configured with four hot plates 211could be reconfigured to include the preheat plate 241 and only threehot plates 211 (FIGS. 8 and 10), which can be replaced by the additionalbrushes 239 as discussed above. Alternatively, the system 200 could beconfigured with four hot plates 211 (FIG. 7) and the preheat plate 241.In the illustrated embodiment, the lug belts 215 can carry the pusherlugs 219 and the chain flights 219 upwardly from the preheat plate 241on upstream guide wheels 243 (FIGS. 8 and 10-11B). The preheat plate 241could be omitted or could be otherwise arranged, shaped, positioned, orconfigured without departing from the scope of the disclosure.

In operation, the package feeder 201 can receive the open-ended packages160 (e.g., with the formed reinforcing sleeve 5 and the attachedopen-ended tube portion 147) from the system 100 or from another sourceand can feed the open-ended packages 160 onto the lug belts 215 at theupstream end of the package conveyor 203 (e.g., FIGS. 6-8, 11A, and11B). In one embodiment, the lug belts 215 can move a pair of the pusherlugs 217 and associated chain flight 219 in the return direction R onthe return side of the package conveyor 203 (e.g., on the underside ofthe package conveyor 203) so that at least the seal edge 229 of thechain flight engages the preheat plate 241 (FIG. 15) and moves along theupper surface 242 of the preheat plate 241 to warm up at least a portionof the chain flight 219. As shown in FIGS. 10-11B, the lug belts 215 canmove the pair of pusher lugs 217 and associated chain flight 219upwardly at the upstream guide wheels 243 while the open-ended package160 fed from the package feeder 201 (FIGS. 6-8) can be positioned on thelug belts 215 downstream from the pair of pusher lugs 217 and theassociated preheated chain flight 219 (FIGS. 10, and 11A). As the lugbelts 215 move continuously in the downstream direction, the open-endedpackage 160 disposed thereon can engage the brushes 237 and/or thebrushes 239 (FIG. 11A), which can help keep the open-ended package 160aligned with the machine direction M and can help prevent the packagefrom moving forward with the lug belts 215 (e.g., due to friction) untilthe pair of pusher lugs 217 and the associated chain flight 219 catch upto and engage the package (FIG. 11B).

As shown in FIGS. 10-13, the engaging surfaces 227 of the chain flights219 can engage the bottom edge 53 of the sleeve 5 to push the open-endedpackage 160 forward against the brushes 237 and/or 239. As shown inFIGS. 12 and 13, when the engaging surfaces 227 engage the bottom edge53, the chain flight 219 can engage the open-ended package 160 so thatthe recessed surface 221 of the chain flight 219 engages theundersurface of the sleeve 5 adjacent the bottom edge 53 and at leastthe seal edge 229 can engage the tail section 73 of the open-ended tubeportion 147. In addition to the brushes 237, 239 slowing or stopping theforward movement of the open-ended package 160 until the chain flights219 engage the sleeve 5, at least the brushes 237 can push downwardly onthe upper surface of the sleeve 5, which can help retain the tailsection 73 of the open-ended tube portion 147 against the chain flight219 and can help urge the remainder of the open-ended tube portion 147downwardly toward the support rails 231 (FIG. 13). Accordingly, in theillustrated embodiment, the tail section 73 engages the oblique surface225, the upper surface 223, and the seal edge 229 of the chain flight219 to be raised above the remainder of the open-ended package 160(FIGS. 12 and 13). As the lug belts 215 continue to move the pusher lugs217 and the chain flight 219 downstream, the pusher lugs 217 and chainflights 219 can move the open-ended packages 160 in the downstreamdirection while the brushes 237 help to retain the sleeve 5 in contactwith the engaging surfaces 227 and to push the open-ended packages 160downwardly. As shown in FIG. 13, as the open-ended packages 160 aremoved in the machine direction M, they pass under the hot plates 211. Inone embodiment, the downward urging on the open-ended packages 160 bythe brushes 237 can help keep the portion of the open-ended tube portion147 that is not to be sealed spaced apart from the bottom surfaces 232of the hot plates 211 as the open-ended packages 160 move under the hotplates 211 on the package conveyor 203. Accordingly, the brushes 237 canhelp prevent undesired sealing of the open-ended tube portion 147.

In the illustrated embodiment, the hot plates 211 can be positioned overthe package conveyor 203 so that the seal edge 229 of the chain flight219 urges at least a portion of the tail section 73 against the bottomsurfaces 232 of the hot plates 211 as the open-ended packages 160 aremoved in the downstream direction M by the package conveyor 203 (FIG.13). In an exemplary embodiment, the chain flight 219 and the hot plates211 can be configured to squeeze the tail section 73 therebetween (e.g.,the seal edge 229 of the chain flight 219 can press a portion of thetail section 73 against the bottom surfaces 232 of the hot plates 211).In one embodiment, the temperature of the hot plates 211, the number ofhot plates 211 included, and the speed of the package conveyor 203 canbe coordinated according to the a desired dwell time for forming theseal 69 in the tail section 73 between the seal edge 229 of the chainflight 219 and the bottom surfaces 232 of the hot plates 211. In anexemplary embodiment, the sealing system 200 can be configured with thehot plates heated to approximately 365 degrees Fahrenheit with a dwelltime of approximately 0.75 seconds. Further, in this example, the chainflight 219 can be preheated on the preheat plate 241, which can beheated to approximately 170 degrees Fahrenheit. Accordingly, thisexemplary configuration of the sealing system 200 can form the seal 69in the tail section 73, which includes two layers of material (e.g.,between the gussets 60) to four layers of material (e.g., at the gussets60) in the illustrated embodiment. In one embodiment, the parameters ofthe sealing system 200 can be adjusted to affect the formation of theseal 69 by adding or subtracting hot plates 211 and/or preheat plates241, using different sized hot plates 211 and/or preheat plate 241,changing the temperature of the hot plates 211 and/or the preheat plate241, and/or adjusting the speed of the package conveyor 203.

In the illustrated embodiment, as the chain flight 219 presses theportion of the tail section 73 against the bottom surfaces 232 of thehot plates 211 and as the package conveyor 203 moves the open-endedpackage 160 in the machine direction M, the upper surface of the tailsection 73 slides along the bottom surfaces 232 (FIG. 13) so that theheat of the hot plates 211 on the upper surface of the tail section 73,the heat of the preheated chain flights 219 on the bottom surface of thetail section 73, and the pressure between the hot plates 211 and thechain flight 219 on the tail section 73 can cause the contacting innersurfaces of the open-ended tube portion 147 (e.g., coated withpolyethylene or another suitable heat seal material) to soften and atleast partially melt to a molten state by the time the tail section 73and the chain flight 219 reach the end of the last hot plate 211. Asshown in FIG. 14, as the tail section 73 passes by the downstream end ofthe last hot plate 211, at least the seal portion SP of the tail section73 that will include the seal 69 contacts the surface of the nip roll236 and the seal edge 229 of the chain flight 219 presses the tailsection 73 against the nip roll 236. In one embodiment, the nip roll 236rotates as the chain flight 219 and the tail section 73 move in thedownstream direction M under the nip roll 236 and the compliant cover ofthe nip roll 236 at least partially conforms to the shape of the tailsection to accommodate the different thicknesses of the differentportions of the tail section (e.g., the tail section 73 can be thickerat the gussets 60 and the seam 71 than at its other portions).Accordingly, the nip roll 236 can apply sealing nip pressure across theentire width or substantially the entire width of the tail section 73against the chain flight 219 to cause the softened and/or molten coatedinner surfaces of the tail section 73 to at least partially fusetogether to form the seal 69.

In one embodiment, the open-ended tube portion 147 is formed into thebag 3 by the at least partial fusing of the inner surfaces of the sealportion of the tail section 73 to form the seal 69, with the closed end9 (FIGS. 1, 3, 4, and 10), and the resultant reinforced package 1 isoutput onto an output conveyor 245 (FIGS. 6 and 8) as the pusher lugs217 and the chain flight 219 are carried downwardly on two downstreamguide wheels 247 (FIGS. 7, 8, 10, and 14) to be returned to the upstreamend of the package conveyor 203 on the underside of the package conveyor203. In one embodiment, the output conveyor 245 can transport thereinforced packages 1 for collection, further handling or processing,storage, and/or shipping to a customer.

As shown in FIG. 8, the pivot frame 213 can be pivoted to the openposition at the hinges 233 to allow retooling or other adjustments tothe sealing system 200. For example, the sealing system 200 can bemodified to change the number and/or spacing of the pusher lugs 217 andchain flights 219, to change the number and/or size of the hot plates211 and/or the brushes 237, 239, and/or to change other features whilethe pivot frame 213 is in the open position. In one embodiment, the openposition of the pivot frame 213 can help make adjustments to the sealingsystem easier by providing access to the heating assembly 205 and thepackage conveyor 203, which are less accessible in the closed positionof the pivot frame 213 due to their location between the pivot frame 213and the base frame 206. In the illustrated embodiment, the pivot frame213 can be pivoted at the hinges 233 to close the sealing system 200 andprepare the system for operation. As shown in FIG. 13, as the pivotframe 213 is moved to the closed position, the hot plates 211 movetoward the package conveyor 203 so that the bottom surfaces 232 of thehot plates 211 engage at least the seal surfaces 229 of the chainflights 219 so that portions of the tail section 73 of the open-endedtube portion 147 is pressed between the bottom surfaces 232 and therespective chain flight 219 during operation of the sealing system 200as described above.

The sealing system could be otherwise arranged, shaped, positioned, orconfigured without departing from the scope of the disclosure and thereinforced packages 1 could be otherwise formed without departing fromthe scope of the disclosure. For example, the sealing system 200 couldbe incorporated into the system 100 (e.g., before the cutting assembly151) in an alternative embodiment.

Generally, as described herein, bags can be formed from a paper stockmaterial, although various plastic or other bag materials also can beused, and can be lined or coated with a desired material. Thereinforcing sleeves described herein can be made from a more rigidmaterial such as a clay-coated natural kraft (“CCNK”). Other materialssuch various card-stock, paper, plastic or other synthetic or naturalmaterials also can be used to form the components of the packagesdescribed herein.

In general, the blanks of the present disclosure may be constructed frompaperboard having a caliper so that it is heavier and more rigid thanordinary paper. The blank can also be constructed of other materials,such as cardboard, or any other material having properties suitable forenabling the carton to function at least generally as described above.The blank can be coated with, for example, a clay coating. The claycoating may then be printed over with product, advertising, and otherinformation or images. The blanks may then be coated with a varnish toprotect information printed on the blanks. The blanks may also be coatedwith, for example, a moisture barrier layer, on either or both sides ofthe blanks. The blanks can also be laminated to or coated with one ormore sheet-like materials at selected panels or panel sections.

As an example, a tear line can include: a slit that extends partiallyinto the material along the desired line of weakness, and/or a series ofspaced apart slits that extend partially into and/or completely throughthe material along the desired line of weakness, or various combinationsof these features. As a more specific example, one type tear line is inthe form of a series of spaced apart slits that extend completelythrough the material, with adjacent slits being spaced apart slightly sothat a nick (e.g., a small somewhat bridging-like piece of the material)is defined between the adjacent slits for typically temporarilyconnecting the material across the tear line. The nicks are brokenduring tearing along the tear line. The nicks typically are a relativelysmall percentage of the tear line, and alternatively the nicks can beomitted from or torn in a tear line such that the tear line is acontinuous cut line. That is, it is within the scope of the presentdisclosure for each of the tear lines to be replaced with a continuousslit, or the like. For example, a cut line can be a continuous slit orcould be wider than a slit without departing from the presentdisclosure.

In accordance with the exemplary embodiments, a fold line can be anysubstantially linear, although not necessarily straight, form ofweakening that facilitates folding there along. More specifically, butnot for the purpose of narrowing the scope of the present disclosure,fold lines include: a score line, such as lines formed with a bluntscoring knife, or the like, which creates a crushed or depressed portionin the material along the desired line of weakness; a cut that extendspartially into a material along the desired line of weakness, and/or aseries of cuts that extend partially into and/or completely through thematerial along the desired line of weakness; and various combinations ofthese features. In situations where cutting is used to create a foldline, typically the cutting will not be overly extensive in a mannerthat might cause a reasonable user to incorrectly consider the fold lineto be a tear line.

The above embodiments may be described as having one or more panelsadhered together by glue during erection of the carton embodiments. Theterm “glue” is intended to encompass all manner of adhesives commonlyused to secure carton panels in place.

The foregoing description of the disclosure illustrates and describesvarious embodiments. As various changes could be made in the aboveconstruction without departing from the scope of the disclosure, it isintended that all matter contained in the above description or shown inthe accompanying drawings shall be interpreted as illustrative and notin a limiting sense. Furthermore, the scope of the present disclosurecovers various modifications, combinations, alterations, etc., of theabove-described embodiments. Additionally, the disclosure shows anddescribes only selected embodiments, but various other combinations,modifications, and environments are within the scope of the disclosureas expressed herein, commensurate with the above teachings, and/orwithin the skill or knowledge of the relevant art. Furthermore, certainfeatures and characteristics of each embodiment may be selectivelyinterchanged and applied to other illustrated and non-illustratedembodiments of the disclosure.

What is claimed is:
 1. A method of sealing reinforced packages, the method comprising: moving an open-ended package in a downstream direction on a package conveyor, the open-ended package including a reinforcement sleeve attached to a tube portion so that a tail section of the tube portion extends from an edge of the reinforcement sleeve and comprises a seal portion, the moving the open-ended package comprising engaging the open-ended package with a flight of the package conveyor moving in the downstream direction; forming a bag with a closed end by engaging at least the seal portion of tube portion between the flight of the package conveyor and a heating element positioned adjacent the package conveyor, the flight moving with the tail section in the downstream direction relative to the heating element, the forming the bag comprising transferring thermal energy from at least the heating element to the tail section to at least partially form a seal along the seal portion in the tail section to at least partially form the closed end of the bag.
 2. The method of claim 1, wherein the transferring thermal energy from at least the heating element to the tail section is during the engaging at least the seal portion of the tail section between the flight and the heating element.
 3. The method of claim 1, wherein the tube portion is oriented so that the tail section is disposed upstream from the reinforcement sleeve.
 4. The method of claim 1, wherein the flight comprises a recessed surface that at least partially engages the reinforcement sleeve.
 5. The method of claim 4, wherein the flight comprises a seal edge that at least partially engages the seal portion of the tail section, the seal edge is spaced upwardly from the recessed surface so that at least the seal portion of the tail section is elevated with respect to the recessed surface, the engaging at least the seal portion between the flight and the heating element comprises engaging at least the seal portion of the tail section between the seal edge and a bottom surface of heating element.
 6. The method of claim 1, further comprising retaining the open-ended package in engagement with the flight by engaging a retention apparatus with the open-ended package.
 7. The method of claim 6, wherein the retention apparatus presses downwardly on at least a portion of the reinforcement sleeve so that at least the reinforcement sleeve is spaced downwardly from the heating element.
 8. The method of claim 6, wherein the retention apparatus comprises at least a brush that drags against at least the reinforcement sleeve as the package conveyor moves the open-ended package in the downstream direction to at least partially retain the open-ended package in engagement with the flight.
 9. The method of claim 1, wherein the package conveyor comprises two spaced lug belts, a lug extends from each of the lug belts, and the flight is mounted to the lugs so that the flight extends between the lug belts.
 10. The method of claim 9, wherein the tail section of the open-ended package engages the flight between the lugs, portions of the reinforcement sleeve extend over the lug belts downstream from the lugs, and the moving the open-ended package in the downstream direction on the package conveyor comprises engaging the edge of the reinforcement sleeve with an engagement surface of the flight as the flight is moved in the downstream direction by the lug belts via the lugs.
 11. The method of claim 10, further comprising retaining the edge of the reinforcement sleeve in engagement with the engagement surfaces of the flight with a retention apparatus, wherein the retention apparatus comprises at least a brush mounted along the downstream direction, the retaining the edge of the reinforcement sleeve in engagement with the engagement surfaces of the flight comprising engaging the reinforcement sleeve with the brush so that the brush drags against the reinforcement sleeve as the package conveyor moves the open-ended package in the downstream direction.
 12. The method of claim 10, further comprising retaining the edge of the reinforcement sleeve in engagement with the engagement surfaces of the flight with a retention apparatus, wherein the seal portion of the tail section engages the flight along a seal edge that is spaced upwardly from the lug belts, and the retaining the edge of the reinforcement sleeve in engagement with the engagement surfaces of the flight comprises pressing downwardly on the reinforcement sleeve against the lug belts with the retention apparatus so that the seal portion of the tail section is spaced upwardly from the reinforcement sleeve.
 13. The method of claim 1, wherein the heating element is one of a plurality of hot plates mounted along the downstream direction above the packaging conveyor and the engaging at least the seal portion of the tail section between the flight and the heating element comprises engaging at least the seal portion between the flight and each hot plate of the plurality of hot plates as the package conveyor moves the open-ended package in the downstream direction.
 14. The method of claim 1, further comprising preheating the flight by engaging the flight with a preheat plate at an upstream end of the package conveyor prior to the engaging the open-ended package with the flight.
 15. The method of claim 1, further comprising nipping at least the seal portion of the tail section between the flight and a nip roller, the nip roller being positioned downstream from the heating element.
 16. A system for sealing reinforced packages, the system comprising: a package conveyor comprising a flight moving in a downstream direction, the flight engaging an open-ended package received by the package conveyor and moving the open-ended package in the downstream direction, the open-ended package including a reinforcement sleeve attached to a tube portion so that a tail section of the tube portion extends from an edge of the reinforcement sleeve and comprises a seal portion; and a heating assembly comprising a heating element positioned adjacent at least a portion of the package conveyor so that at least the seal portion of the tube portion is engaged between the flight and the heating element when the package conveyor moves the open-ended package in the downstream direction, wherein the heating element is at least partially heated for transferring thermal energy to the tail section for at least partially forming a seal in the tail section.
 17. The system of claim 16, wherein the flight comprises a recessed surface that at least partially engages the reinforcement sleeve.
 18. The system of claim 17, wherein the flight comprises a seal edge that at least partially engages the seal portion of the tail section, the seal edge is spaced upwardly from the recessed surface so that at least the seal portion of the tail section is elevated with respect to the recessed surface, and the seal portion of the tail section is engaged between the seal edge and a bottom surface of the heating element as the package conveyor moves the open-ended package in the downstream direction.
 19. The system of claim 16, further comprising a retention apparatus that engages the open-ended package to at least partially retain the open-ended package in engagement with the flight.
 20. The system of claim 19, wherein the retention apparatus presses downwardly on at least a portion of the reinforcement sleeve so that at least the reinforcement sleeve is spaced downwardly from the heating element.
 21. The system of claim 19, wherein the retention apparatus comprises at least a brush that drags against at least the reinforcement sleeve as the package conveyor moves the open-ended package in the downstream direction to at least partially retain the open-ended package in engagement with the flight.
 22. The system of claim 16, wherein the package conveyor comprises two spaced lug belts, a lug extends from each of the lug belts, and the flight is mounted to the lugs so that the flight extends between the lug belts.
 23. The system of claim 22, wherein the tail section of the open-ended package engages the flight between the lugs, portions of the reinforcement sleeve extend over the lug belts downstream from the lugs, and the edge of the reinforcement sleeve engages an engagement surface of the flight as the flight is moved in the downstream direction by the lug belts via the lugs.
 24. The system of claim 23, further comprising a retention apparatus that retains the edge of the reinforcement sleeve in engagement with the engagement surfaces of the flight, wherein the retention apparatus comprises at least a brush mounted along the downstream direction, the brush engaging the reinforcement sleeve and drags against the reinforcement sleeve as the package conveyor moves the open-ended package in the downstream direction.
 25. The system of claim 23, further comprising a retention apparatus that retains the edge of the reinforcement sleeve in engagement with the engagement surfaces of the flight, wherein a seal edge of the flight engages the seal portion of the tail section, the seal edge is spaced upwardly from the lug belts, and the retention apparatus presses downwardly on the reinforcement sleeve against the lug belts so that the seal portion of the tail section is spaced upwardly from the reinforcement sleeve.
 26. The system of claim 16, wherein the heating element is one of a plurality of hot plates mounted along the downstream direction above the packaging conveyor and the seal portion is engaged between the flight and each hot plate of the plurality of hot plates as the package conveyor moves the open-ended package in the downstream direction.
 27. The system of claim 16, further comprising a preheat plate at an upstream end of the package conveyor, the preheat plate being positioned to engage the flight for preheating the flight.
 28. The system of claim 16, further comprising a nip roller positioned downstream from the heating element for engaging at least a portion of the tail section when the tail section is in engagement with the flight as the package conveyor moves the open-ended package in the downstream direction for nipping at least the seal portion of the tail section between the nip roller and the flight.
 29. The system of claim 16, wherein the package conveyor is mounted to a base frame and the heating element is mounted to a pivot frame, and the pivot frame is mounted to the base frame at at least a hinge so that the pivot frame is pivotable away from the package conveyor. 